CN1535404A - Proportional band temp control for one or more heating elements - Google Patents
Proportional band temp control for one or more heating elements Download PDFInfo
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- CN1535404A CN1535404A CNA018216943A CN01821694A CN1535404A CN 1535404 A CN1535404 A CN 1535404A CN A018216943 A CNA018216943 A CN A018216943A CN 01821694 A CN01821694 A CN 01821694A CN 1535404 A CN1535404 A CN 1535404A
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Images
Classifications
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B1/00—Details of electric heating devices
- H05B1/02—Automatic switching arrangements specially adapted to apparatus ; Control of heating devices
- H05B1/0227—Applications
- H05B1/0252—Domestic applications
- H05B1/0275—Heating of spaces, e.g. rooms, wardrobes
- H05B1/0283—For heating of fluids, e.g. water heaters
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/10—Control of fluid heaters characterised by the purpose of the control
- F24H15/144—Measuring or calculating energy consumption
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/10—Control of fluid heaters characterised by the purpose of the control
- F24H15/156—Reducing the quantity of energy consumed; Increasing efficiency
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/10—Control of fluid heaters characterised by the purpose of the control
- F24H15/174—Supplying heated water with desired temperature or desired range of temperature
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/20—Control of fluid heaters characterised by control inputs
- F24H15/212—Temperature of the water
- F24H15/223—Temperature of the water in the water storage tank
- F24H15/225—Temperature of the water in the water storage tank at different heights of the tank
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/20—Control of fluid heaters characterised by control inputs
- F24H15/254—Room temperature
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/20—Control of fluid heaters characterised by control inputs
- F24H15/281—Input from user
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/30—Control of fluid heaters characterised by control outputs; characterised by the components to be controlled
- F24H15/355—Control of heat-generating means in heaters
- F24H15/37—Control of heat-generating means in heaters of electric heaters
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/30—Control of fluid heaters characterised by control outputs; characterised by the components to be controlled
- F24H15/395—Information to users, e.g. alarms
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/40—Control of fluid heaters characterised by the type of controllers
- F24H15/407—Control of fluid heaters characterised by the type of controllers using electrical switching, e.g. TRIAC
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/40—Control of fluid heaters characterised by the type of controllers
- F24H15/414—Control of fluid heaters characterised by the type of controllers using electronic processing, e.g. computer-based
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H9/00—Details
- F24H9/20—Arrangement or mounting of control or safety devices
- F24H9/2007—Arrangement or mounting of control or safety devices for water heaters
- F24H9/2014—Arrangement or mounting of control or safety devices for water heaters using electrical energy supply
- F24H9/2021—Storage heaters
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G05D23/00—Control of temperature
- G05D23/19—Control of temperature characterised by the use of electric means
- G05D23/1906—Control of temperature characterised by the use of electric means using an analogue comparing device
- G05D23/1909—Control of temperature characterised by the use of electric means using an analogue comparing device whose output amplitude can only take two discrete values
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/78—Heating arrangements specially adapted for immersion heating
- H05B3/82—Fixedly-mounted immersion heaters
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/20—Control of fluid heaters characterised by control inputs
- F24H15/242—Pressure
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- Computer Hardware Design (AREA)
- Heat-Pump Type And Storage Water Heaters (AREA)
- Control Of Resistance Heating (AREA)
Abstract
A water heater having a water tank (11, 205) and multiple electric resistance heating elements (16, 125, 235, 240) extending into the water tank for heating water in the tank. The water heater includes a proportional band temperature controller (260) for conducting electric power to the electric resistance heating elements (16, 125, 235, 240) in bursts. Each burst of electric power is followed by a period during which the temperature controller does not conduct power to the electric resistance heating elements (16, 125, 235, 240). In one embodiment, each burst of electrical power lasts for about 95% or less of a cycle comprised of one burst of electric power followed by the period during which the temperature controller does not conduct electric power. Further, activation of the heating elements by the controller is carried out in a sequential or other timed or controlled fashion to permit uniform heating of the water in the tank.
Description
Related application
The present invention is the continuation application of the United States Patent (USP) 09/361825 of application on August 17th, 1999.
Technical field
The present invention relates generally to electric heater.More specifically, thus carry electric power to improve the method and apparatus of the efficiency of heating surface of water heater in some sense to stratie with the present invention relates to be used to pulse.
Background technology
Storage-type water heater generally includes: the permanent closure water tank; Cylinder blanket, it is coaxial and diametrically away from water tank, to form annulus between tank outer wall and outer casing inner wall with water tank; And thermal insulation material, it is positioned at the part of annulus at least, to provide heat insulation to water tank.Water tank has multiple annex, as water inlet, water delivering orifice and drainage arrangement.In addition, water heater also has water heating and temperature control system.Water heating and temperature control system comprise stratie.This heating element extends through the device in the water tank wall, makes heating element in water tank.Heating element is connected to the outer power supply of water tank.
Existing water heating and temperature control system further comprise mechanical thermostat usually.When the water in detecting water tank was lower than the set-point temperature of selection, the mechanical thermostat off switch was so that electric power is passed through stratie; And when the water in the water tank is in or be higher than the set-point temperature, open switch to stop electrical power flow through stratie.The electric power of stratie of flowing through or fully conducting perhaps close fully to flow through electric current completely.Because change and hysteresis phenomenon during mechanical thermostat is made, so water temperature is with the set-point temperature of " overshoot (overshoot) " expectation.In other words, even water heating and temperature control system make that stratie also continues the water in the heating water tank when water temperature is higher than the set-point temperature.The overshoot that prevents or limit existing water heater will be useful.
Summary of the invention
Therefore, the invention provides a kind of water heater with controller, this controller is used for regulating the electric power that flows to stratie with controlled pulse (pulse) or train of impulses (burst) form.Provide electric power to make with pulse or train of impulses to heating element, greatly reduce and add the used electric power of hot water the water of equivalent is heated to the temperature of selection with the mechanical temperature controller speed much at one of prior art.Therefore, the adjusting of electric power has improved the efficient of water heater.
Adjusting is a proportional band temperature controller of having considered the specific characteristic mark (signature) of water heater by use with the method for optimizing that burst flows to the electric power of resistive element.That is, offer the pulse of electric power string of heating element and not when this element provides modulation voltage between time period of electric power, water heater can change modulation voltage according to many variablees or water heater characteristic when calculating.These variablees can include but not limited to: the surrounding room temperature of the physical environment that the parts number of installing in the position of heater element power, element watt density, heating element, the water tank, the operating voltage of water heater, water inlet water temperature, water tank capacity, water heater are installed and the use-pattern of using the facility of well heater.By all these aspects are combined with the proportional band technology, obtain surpassing the obvious energy-saving effect of existing electric heater.
The present invention further provides water heater, having comprised: water tank is used to hold water; Water inlet pipe, it has the water inlet of cold water being introduced water tank; Rising pipe, it has the water delivering orifice of discharging the water that has heated from water tank; With first heating element, it extends into water tank.Water heater further comprises control circuit, can operate this control circuit and control with the electric power supply of train of impulses to heating element.All follow the time period that electric power does not supply to heating element behind each train of impulses.
In one embodiment, water tank has the water tank characteristic, and heating element has element characteristic, and control circuit comprises temperature sensor, can operate this temperature sensor to detect the water temperature in the water tank.Control circuit further comprises the controller that communicates with heating element and temperature sensor.Can operation control receive detected temperatures, calculate the heating strategy of water heater based on element characteristic and/or water tank characteristic, and respond this heating strategy and generate the signal that starts heating element with part from temperature sensor.In another embodiment, further the operation control circuit response detects at least one item in water temperature and element characteristic, water tank characteristic, water tank external temperature, water uniformity coefficient (consistency) and the water history and changes dutycycle.
The present invention even the method for water temperature in the control water heater further is provided.This method comprises the element characteristic of determining heating element, detect water temperature in the water tank, to small part based on element characteristic and water temperature calculate the performance number that will provide to heating element, and with this performance number from power delivery to heating element.Calculation procedure can also to small part based on water tank characteristic, environment (being surrounding environment) temperature or water characteristic (being temperature, hardness etc.).
The present invention further provides the software program that is used to generate signal, wherein this signal causes power to be transferred to heating element.This software program generates this signal by obtain the water heater code from storage unit.The water heater code to small part based on heating element characteristic or water tank characteristic.Software program comprises that further reception calculates the performance number that will transfer to heating element, and generates the signal that causes this performance number is supplied with heating element based on water heater code and sensing temperature from the fluid temperature of temperature sensor, to small part.
Persons skilled in the art can be expressly understood other features and advantages of the present invention from following detailed description, claim and accompanying drawing.
Description of drawings
Fig. 1 is a cut-open view of realizing water heater of the present invention, has shown the layout that temperature controller of the present invention is relevant with the water heater other parts.
Fig. 2 is circuit theory diagrams of realizing temperature controller of the present invention.
Fig. 3 is the mechanical temperature controller of prior art and the electricity consumption data plot of proportional band temperature controller of the present invention.
Fig. 4 is the mechanical temperature controller of prior art and the consumption rate data plot of proportional band temperature controller of the present invention.
Fig. 5 realizes the sectional view with another water heater of a plurality of heating elements of the present invention.
Fig. 6 realizes the sectional view of a water heater again with a plurality of heating elements of the present invention.
Fig. 7 is the fragmentary cross-sectional view of the water heater shown in Fig. 6.
Fig. 8 realizes the sectional view that comprises the water heater of controller of the present invention.
Fig. 9 is the part enlarged drawing of the controller shown in Fig. 8.
Figure 10 is the principle schematic of the control circuit shown in Fig. 8.
Figure 11 is the electrical schematic diagram that is used for the power supply of the control circuit shown in Figure 10.
Figure 12 is the electrical schematic diagram of the zero-crossing detector of the control circuit shown in Figure 10.
Figure 13 is the electrical schematic diagram of the low voltage resetting circuit of the control circuit shown in Figure 10.
Figure 14 is the electrical schematic diagram of the temperature sensing circuit of the control circuit shown in Figure 10.
Figure 15 is the electrical schematic diagram of the temperature controller of the control circuit shown in Figure 10.
Figure 16 (a) and 16 (b) are the electrical schematic diagrams of the each several part of the control circuit shown in Figure 10.
Figure 17 is the electrical schematic diagram that is used for the oscillator of the control circuit shown in Figure 10.
Figure 18 is the process flow diagram of the method for the water heater shown in the expression control chart 8.
Figure 19 is that expression is used to carry out test to determine the process flow diagram of the exemplary method whether heating element is submerged.
Figure 20 a, 20b, 20c and 20d are that expression is carried out the pick-up transducers sample, calculates water temperature, calculated the temperature controller setting, the change operator scheme under the situation of needs, state and the process flow diagram each several part of exemplary method of the step of heating priority is set heating cycle is set.
Figure 21 is the process flow diagram of expression 800ms interrupt event.
Before in detail explaining one embodiment of the present of invention, should be appreciated that the invention is not restricted to propose in the following description or accompanying drawing in CONSTRUCTED SPECIFICATION and the parts arrangement described.The present invention can otherwise implement, and can or realize with the several different methods practice.And should be appreciated that word used herein and term be used to describe and should not be considered to as limiting." comprising " used herein and " comprising " and their distortion representative comprise bar item and equivalent and the additional strip item of listing thereafter.Used herein " by ... constitute " and the distortion representative only comprise the bar item of listing thereafter.
Embodiment
As mentioned above, usage ratio band temperature controller has unexpected advantage in having the water heater of stratie, water in the water heater is heated to the set-point temperature of preliminary election, and than in the identical water heater of the mechanical temperature controller that uses prior art, the water of equivalent being heated to identical set-point temperature little power consumption.
A kind of exemplary proportional band temperature controller is a kind of electronic equipment, comprising: water temperature sensing equipment (thermistor); Temperature set points equipment (variohm); Gated thyristor is used for electric power is switched to stratie; And logical circuit, be used to respond from the signal of water temperature sensing equipment and temperature set points equipment and control thyristor.Logical circuit receives the voltage input from water temperature sensing equipment and temperature set points equipment, the gap between its indicating water temperature and the set-point temperature.The logical circuit response is signaled gated thyristor from the voltage input of water temperature sensing equipment and temperature set points equipment.The big situation of the temperature difference between water temperature sensing equipment and temperature set points equipment, logical circuit is signaled gated thyristor and is conducted electricity in the major part of each round-robin of AC electric current about 94%, and signal gated thyristor in each AC round-robin about 6%, stop the conduction.Along with the temperature difference between water and the set-point diminishes, water temperature enters the proportional control band, and logical circuit begins to apply more control to gated thyristor in the proportional control band, with the power supply of restriction to stratie.Along with water temperature enters the proportional control band, logical circuit is set up new Control Circulation, and signals thyristor conduct electrical power in each round-robin 85%, and stops conduction in each round-robin 15%.Along with the close set-point of water temperature temperature, logical circuit is signaled thyristor and is still less conducted electricity in the time at each round-robin.When water temperature reached the set-point temperature, logical circuit was closed thyristor, and electric power is not provided to stratie, was lower than the set-point temperature once more until water temperature.For fear of near the unsuitable circulation the temperature of set-point, before signaling the thyristor conduct electrical power once more and water heating returned to the set-point temperature, logical circuit is set to make water temperature to drop to be lower than 5 ° to 10 of set-point temperature.
This efficient raising of in the water heater of usage ratio band temperature controller water being heated is not entirely understood.In theory, the electric power of all supply straties all will be converted into heat in essence, and heat should be transferred to the water around stratie.The electric power of equivalent should with etc. the identical temperature of water heating of weight.Shown in following Example, the water heater with proportional band temperature controller is heated to the required electric power of selected set-point temperature with the water of a water tank and lacks about 10% than the identical water heater with mechanical temperature controller of prior art.Be used for some efficiency improvement of having solved the mechanical temperature controller with the improvement of proportional band temperature controller on accuracy that seldom overshoot makes water reach the set-point temperature, but do not solve all.
Although do not wish to be limited, my suggestion raising on the efficiency of heating surface when usage ratio band temperature controller comes from the physical condition in the water tank, and this physical condition has influenced the heat transmission from stratie to water.The proportional band temperature controller conducts to stratie with burst with electric power, and the water in water tank reaches selected set-point temperature, and wherein said burst heel is with the brief period of non-conducting electric power.When water reached the set-point temperature, the proportional band temperature controller stopped exactly to the stratie conduct electrical power.On the other hand, the mechanical temperature controller of prior art continues with full power to the stratie conduct electrical power during water is heated.When water reached the set-point temperature, the mechanical property of bimetallic thermocouple may cause the overshoot of mechanical temperature controller, and heated water to the temperature that is higher than the set-point temperature before stopping that electric power conducted to stratie.
The stratie that uses in the family expenses water heater is heated to 800 temperature to 900 scopes within several seconds.The water that contacts with such thermal resistance heating element may depend on tank pressure and evaporate, and may form one deck steam around stratie and reduces from the heat of stratie transmission feedwater.In the mechanical temperature controller, stratie is heated like this and is kept high temperature, cuts off the electricity supply until bimetallic thermocouple.May be radiated through water tank wall from stratie and by the heat that the mechanical temperature controller is controlled, maybe may be transferred into tank top by the evaporation convection current, in tank top, unnecessary heat is absorbed by the water away from the temperature sensing bimetallic thermocouple of top layer.
In the proportional band temperature controller, stratie is heated during each train of impulses of electric power, and is cooled by contacting with water in the time period between train of impulses.Cooling to stratie between each train of impulses of electric power has reduced the temperature that stratie improves, and has reduced the electromotive force of the evaporation accumulation around the thermal resistance heating element.So the heat that is passed to water from stratie has increased.Provide the heat transference efficiency of the water of electric power in having improved from the stratie to the water heater with the stratie of discontinuous burst in water heater, wherein each train of impulses heel time period of turn-offing with electric power.
The proportional band temperature controller is known by people and is widely used in many commercial application, comprises the water temperature in the device of control as coffee machine.As far as I know, the proportional band temperature controller is not applied to the temperature of the cardinal principle ponding in the control store type water heater as yet.
Fig. 1 has shown the cut-open view of water heater 10, and water heater 10 comprises: permanent closure water tank 11, around the shell 12 of water tank 11 with fill the foam insulation 13 of the annular space between water tank 11 and the shell 12.Water inlet pipe or dip-tube 14 and rising pipe 15 enter the top of water tank 11.Water inlet pipe 14 has near the water inlet 22 that is used for adding cold water the bottom of water tank 11.Rising pipe 15 has the water delivering orifice 24 that is used near the discharge hot water top of water tank 11.Stratie 16 extends through the wall of water tank 11.Proportional band control circuit in the control box 17 is connected to stratie 16.Thermistor 18 contacts with the outer wall of water tank 11 to detect the water temperature in the water tank 11, and it is connected to logical circuit by electric wire 19.Alternating current is supplied to gated thyristor by lead 20.Customizable operation-interface can be installed in the outside of water heater, to communicate and to be provided for to control the safeguard protection visit of heating element with control box 17.But the operating operation interface is to provide the direct or Long-distance Control to heating element.
Fig. 2 is the circuit theory diagrams of preferred proportional band temperature-control circuit 100 of the water that is used for heating water heater of the method according to this invention.In Fig. 2, stratie 125 is the 4500W heating elements that are used for the water of heating water heater.Temperature set points equipment 101 is variohms, is used for temperature set points is arranged in about 90 to 180 scopes.Thermistor 102 is used for detecting the water temperature of water heater.In another embodiment, can in water tank, place a plurality of thermistors everywhere, to measure the water temperature of a plurality of positions.The output of a plurality of thermistors can be by on average.
Gated thyristor 103 is the TRIAC that produced by motorola inc, is used to control to the electric power of stratie 125.Logic chip 104 is the proportional band temperature controller UAA1016A that produced by motorola inc.Supply 240V by lead 105 and 106 to proportional band temperature-control circuit 100.The photoelectrical coupler 108 that will describe below is used to be controlled at the amount of the water temperature that the proportional band temperature-control circuit must descend from the set-point temperature before starting once more.
Be about-the stable power-supplying voltage of 8V enters lead 110 from lead 106 by Zener diode 107 and resistance 109, is supplied to ratio for temperature-control circuit.Voltage drop by temperature set points equipment 101 and temperature sensor 102 produces signal voltage at point 111.The temperature difference between the water temperature of signal voltage and set-point temperature and transmission is proportional.Measuring voltage is transferred to a pin of voltage comparator 113 in the logic chip 104 by lead 112.Generate reference voltage at point 116, its amplitude is by determining by the voltage drop of resistance 114 and 115.The sawtooth voltage that generates in the saw-toothed wave generator 118 in logic chip 104 is applied in reference voltage at point 119.Flow to second pin of voltage comparator 113 by lead 117 by the reference voltage of sawtooth voltage modification.
The sawtooth voltage that puts on reference voltage causes voltage form with sawtooth wave in about 0.85 second cycle at the second pin place of voltage comparator 113 to change to maximum voltage from minimum voltage.In voltage comparator 113, the amended reference voltage at the signal voltage at the first pin place and the second pin place compares.Comparative result transfers to logical circuit 121 by lead 120.In logical circuit 121, the signal flow of generation is used to control thyristor 103 through lead 122, amplifier 123 and lead 124.When the signal voltage at the first pin place of comparer 113 during, will conduct and allow electrical power flow through stratie 125 to the signal of thyristor 103, with the water that is used in the heating water tank greater than the maximal value of the reference voltage at the second pin place of comparer 113.Arrange logic chip 104 so that the signal in the lead 124 make thyristor 103 each ac period 96% in conduction, and each current cycle 4% in stop conduction.
Because the water temperature that temperature sensor 102 detects reaches the set-point temperature of selecting on set-point temperature device 101, the signal voltage at the first pin place of voltage comparator 113 will be brought down below the peaked value of reference voltage at the second pin place of voltage comparator 113.When in the scope of signal voltage between the mean value of the maximal value of reference voltage and reference voltage, temperature-control circuit 100 is in the proportional band range of control.So when signal voltage during greater than the reference voltage level at the second pin place of voltage comparator, logical circuit 121 is signaled amplifier 123, makes it signal thyristor 103 electric power is conducted to stratie 125.Then, along with causing the reference voltage at the second pin place of voltage comparator, sawtooth voltage increases to value greater than the signal voltage value at the first pin place of voltage comparator, logical circuit 121 is signaled amplifier 123, makes it signal thyristor 103 and stops to stratie 125 conduct electrical power.Along with the signal voltage at the first pin place of voltage comparator mean value near the reference voltage at the second pin place of voltage comparator 113, thyristor 103 not conductings in more ratios in each cycle of the sawtooth voltage that generates.When the water temperature that is detected by temperature sensor 102 equals the set-point temperature of temperature set points equipment 101, the signal voltage at the first pin place of voltage comparator 113 will equal the average reference magnitude of voltage at the second pin place of voltage comparator 113, and logical circuit 121 is signaled amplifier 123 cutoff thyristors 103, cuts off the electric power to stratie 125.Thyristor 103 remains nonconducting state, and the water temperature that detects until temperature sensor 102 drops to and is lower than the default amount of set-point temperature, and this will illustrate below.
The reference voltage at the signal voltage at the first pin place of voltage comparator 113 and the second pin place of voltage comparator 113 must have such value, and what it made that logical circuit 121 can produce amplifier 123 can suitably control the signal that thyristor 103 heats water to preferred temperature.Temperature set points equipment 101 is variohms, can its resistance of manual adjustments to change the set-point temperature.Temperature sensor 102 is thermistors, and its resistance raises along with the water temperature that detects and reduces.Select the value of resistance 126 and 127, make the difference between the water temperature of the signal voltage at invocation point 111 places and set-point temperature and detection proportional.The reference voltage at point 116 places determined by the value of resistance 114 and 115, and the amplitude that is applied to the sawtooth voltage of reference voltage in point 119 places is determined by the value of resistance 128 and 129.Must adjust the value of these resistance, to adapt to specific temperature set points equipment 101, temperature sensor 102 and to be the characteristic of the logic chip 104 of proportional band temperature-control circuit 100 selections.
As mentioned above, photoelectrical coupler 108 is included in the proportional band temperature-control circuit 100, to prevent near the inappropriate circulation of the thyristor 103 when the water temperature that detects is the temperature of set-point.When the water temperature that detects equaled the set-point temperature, logical circuit 121 was signaled amplifier 123 cutoff thyristors 103 and is stopped electric power being conducted to stratie 125.If there is not photoelectrical coupler 108, then drop to when being lower than set-point temperature one very little amount and for example being less than 1 ℃ when the water temperature that detects, logical circuit 121 will be signaled amplifier 123 and open thyristor 103 and electric power is conducted to stratie 125, be heated to the set-point temperature once more until the water temperature that detects.This step causes opening rapidly and cutoff thyristor 103, to control the water temperature that detects as far as possible near the set-point temperature.
Operation by lead 130 and 131 photoelectrical couplers 108 that link to each other with stratie 125 circuit makes the temperature that detects when electric current is flowed through stratie 125 seem than actual high about 5 ℃.So when the water temperature of temperature sensor 102 detections reached the set-point temperature, thyristor 103 stopped by stratie 125 and photoelectrical coupler 108 conduction currents.If there is not the electric current photoelectrical coupler 108 of flowing through, the signal voltage of then putting 111 places is by determining through the voltage drop of temperature sensor 102 with through the voltage drop of set-point equipment 101, resistance 126 and resistance 127.The voltage drop equivalence that the voltage drop that resistance 127 generates causes with being changed by about 5 ℃ detected temperatures.So the temperature of detection seems than it actual high about 5 ℃, and before the temperature that the signal voltage indication at the first pin place of voltage comparator 113 detects was lower than the set-point temperature, the temperature of detection must additionally descend 5 ℃.When voltage comparator 113 usefulness signals when logical circuit 121 notice detected temperatures are lower than the set-point temperature, logical circuit 121 is signaled amplifier 123 and is opened thyristor 103 and allow the electric current stratie 125 of flowing through.Along with the electric current stratie 125 of flowing through, electric current is by lead 130 and 131 photoelectrical coupler 108 of flowing through.Along with the electric current photoelectrical coupler 108 of flowing through, resistance 127 is shunted, and has eliminated 5 ℃ of deviations of the measuring water temperature of apparent.Logical circuit 121 is signaled amplifier 123 and is opened thyristor 103 then, reaches the set-point temperature once more until the water temperature that detects.This step of photoelectrical coupler 108 makes at thyristor 103 once more by before stratie 125 conduct electrical power, the temperature that detects is reduced to following about 5 ℃ of set-point temperature, and makes and before the electric power of cutting off stratie 125 water temperature that detects is heated to the set-point temperature.This step has prevented to pass through the current cycle of stratie 125 when the detection water temperature is near the temperature of set-point.
In another embodiment, temperature-control circuit 100 can comprise real-time clock able to programme, and wherein peak or non-peak need energy cycle or clear operation circulation can be programmed to the Control Circulation to heating element.In addition, also can add the sensor that pressure transducer, temperature sensor, mineral deposit (mineral deposit) sensor and/or be used to detects the existence of water.When detecting predetermined condition or restriction, will be programmed for the electric power of disconnection to control circuit from water heater and/or heating element.Further, control circuit can comprise the device that is used to respond different condition and adjusts the set-point automatically, and described different condition is water consumption or be in the peak also need can the cycle on the right and wrong peak for example.
Example
In first example, operation has the water heater of 4500W stratie, is used for using the 240V alternating current that water is heated to 120 °F from 60 °F.In first stroke, use in the application's introductory section, describe can commercial bimetallic temperature controller, to detect water temperature and to control to the electric current of stratie.In second stroke, use the proportional band temperature-control circuit of describing in this application shown in Fig. 2, flow with the electric current that detects water temperature and control to stratie.The comparative result that has shown two strokes among Fig. 3.
For stroke 1, the tension force on the bimetallic temperature controller is regulated by stud bolt, makes bimetallic temperature controller become hemispherical dome structure at 120 temperature place, set-point rapidly from flat structure.The outer wall of bimetallic temperature controller about three inches position contact water-heater water tank above stratie.Bimetallic temperature controller is connected to electric switch in the lead of stratie power supply by insulated shaft.Water tank is full of 60 water, and power supply is connected to the lead that stratie is provided.Bimetallic temperature controller remains flat and electric switch cuts out.Electric current continue about 27 minutes with 19.7 amperes data rate stream through stratie, be heated to about 122 °F until water.Bimetallic temperature controller becomes semisphere rapidly then, and starting switch is cut to the electric current of stratie.Water temperature and time chart have been shown among Fig. 3 for first stroke.
For stroke 2, used the proportional band temperature-control circuit of describing in this application as shown in Figure 2.Set-point equipment 101 is calibrated to 120 temperature in set-point, and thermistor temp sensing equipment 102 about three inches places above stratie 125 are attached to water tank.Thyristor 103 is connected to stratie 125.The water tank of water heater is drained and is refilled 60 water, and proportional band temperature-control circuit 100 is connected to the electric power main line.Proportional band temperature-control circuit 100 provides 18.8 amperes electricity to stratie 125 at first, promptly is approximately 95% of electric current that the mechanical thermostat of stroke 1 provides.After about four minutes (68 °F), the electricity that proportional band temperature-control circuit 100 will be supplied with stratie 125 reduces to 18.6 amperes, promptly is approximately 91% of electric current that the mechanical thermostat of stroke 1 provides.After about 21 minutes (104 °F), the water temperature that detects enters the electric current that proportional band temperature range and 100 beginnings of proportional band temperature-control circuit slowly reduce to stratie 125, the water temperature that detected after 27 minutes reaches the set-point temperature, and proportional band temperature circuit 100 turn-offs the electric current of stratie 125.
The water that the inspection of Fig. 3 has been shown same amount is heated to almost equal temperature in the identical time in stroke 1 and stroke 2.Yet, in stroke 1, need 19.7 amperes of electricity, and in stroke 2, during heating only need about 18.6 amperes of electricity.Promptly, the electric power that adds the hot water needs in the water heater of having equipped proportional band temperature-control circuit of the present invention lacks about 9% than in the identical water heater that uses the mechanical temperature controller water of equivalent being heated to uniform temp, proportional band temperature-control circuit wherein of the present invention is powered to stratie 125 with burst, and the burst heel is with of short duration power-off time section.This is unexpected result.
The electric current that the current impulse that the proportional band temperature-control circuit sends to load makes water temperature to respond to apply and critically improve rapidly and reduce.The short interruption that puts on the electric current of each time period of heating element can make emittance from heating element to the more effective transmission of water.
As second example, carry out the actual amount of a test with the energy determining to use typical hot water heating operation cycle period consumer.With reference to figure 4, actual kilowatt hour (kWh) and time relation have been drawn for mechanical thermostat and the electronic temperature control device that comprises the proportional band steering logic.
Fig. 4 explanation is during typical heat cycles, and the direct result of usage ratio band steering logic is the energy of few usefulness about 3%.The conduction angle of the igniting quadrant (firing quadrant) by changing TRIAC might increase to this number percent about 5-5.5%, and can the performance of water heater do not had a negative impact.
In addition, flow to the electric current of the heating element of usage ratio band steering logic by restriction, and by with pulse to heating installation power supply, slide to temperature set points gradually and not overshoot preferred temperature can reduce by 15% energy consumption again.
With current-modulation and prevent that the overshoot of temperature set points from combining, provide with the running cost of the similar well heater that uses the thermometal mechanical thermostat to the consumer and to have compared 10% energy composite energy saving nearly.
Superheated water can be wasted energy usually by 125-130 reasonable temperature.Typical two feet thick heat insulation layers are being higher than the ability that loses effective maintenance heat under about 130 temperature.This energy loss in standby mode is wasted, and causes the more frequent needs that surpass of well heater cycle index potentially.
Proportional band control circuit of the present invention prevents overshoot, and makes water temperature only descend about 10 °F, the needed difference in set-point that water temperature is returned want with cycle only.
Another advantage of proportional band control circuit is that it is applicable to inflammable steam ambient.For example, there is environment in car repairing depot, workshop or zone, vault with solvent, gasoline, propane or other high inflammability or explosive steam.When setting up or disconnecting when electrically contacting, depend on the magnitude of current of switching, mechanical thermostat and contact-type switchgear may form electric arc.If steam is fully unstable, then electric arc can be lighted inflammable steam.On the contrary, the proportional band control circuit is solid-state fully, does not have movable part, and can not light inflammable steam.
Although the control of the proportional band of above-mentioned realization has advantage, can in having multiple controlled heating element, obtain even the higher efficiency of heating surface.Shown exemplary hot water device 150 among Fig. 5 with this element, it is subjected to the influence of following patent, the name of submitting on August 17th, 1 is called the United States Patent (USP) 09/361825 of PROPORTIONAL BAND TEMPERATURE CONTROL FORMULTIPLE HEATING ELEMENTS, incorporates this patent here into as a reference.Water heater 150 is shared many common elements with water heater 10, and common elements Fig. 1 with 5 in identical Reference numeral representative.Yet different with water heater 10, water heater 150 has a plurality of heating elements 16 and 16 '.Heating element 16 be arranged in water tank than lower part, heating element 16 ' is arranged in the higher part of water tank.Can be by being stored in the control circuit control heating element 16 ' in the control box 17 ', the input that control circuit receives from thermistor or temperature sensor 18 ' by the communication link as electric wire 19 '.Although perhaps do not show, sensor 18 ' and heating element 16 ' can be got in touch with the control circuit that is stored in the control box 17, and can use a controller but not a plurality of circuit.Communication between sensor 18 ' and the heating element 16 ' can be by realizing with the physically parallel communication link (not shown) of lead 20.Under the situation with two heating elements of single controller control, the control circuit in the case 17 can be taked the form of programmable microprocessor.Certainly, if desired, the heating element more than two can be installed in the water heater 150, and they are by such controller control.
No matter use definite control circuit or realized single controller or multi-controller, the heating element among Fig. 5 starts by order or with certain preset frequency or mode, distributes with balance or uniform mode so that be passed to the heat energy of water tank 150.So for example, heating element 16 can work in the very first time of time T 1 section, power offers heating element 16 with above-mentioned pulse or multi-pulse train mode during this time period.Subsequently, element 16 ' can the mode with pulse be activated in time period of time T 2.Depend on specific heating application and condition, time T 1 and T2 may equal in length or are not waited, and may overlap each other or crossover not.In addition, according on the top of water tank 11 or the temperature that detects of bottom, serviceability temperature sensor 18 and 18 ' feedback mechanism may be used to trigger specific heating element.
No matter use what particular order, usage ratio band temperature controller is controlled the inhomogeneous heating that a plurality of elements in the water heater help avoid the water in the water tank.Inhomogeneous heating takes place in the existing heating system usually, and the heating of most of water is finished by being positioned near the heating element in heating water tank bottom in the existing heating system.This structure often causes producing " layering ", and heated water is increased to tank top and overheats, and has formed uneven temperature layer in the bottom of water tank.Worse, because the thermofin 13 in the water tank can not keep the high heat energy from superheated water effectively, so the heat of tank top accumulative total will dissipate rapidly.Utilize described hereinly to the heating of water sequential pulse or train of impulses, the water in the water tank 11 more as one man is heated.This has reduced to take place in the layering from the tank top to the bottom possibility of heat or cold spot.Also reduce the generation of superheated water and improved efficient.
The outlet or the water pipe 155 of the mixing valve 157 by being arranged in dip-tube 14, above-mentioned order can also combine with the controlled introducing of cold water.By communication link V
I/OCan operation valve 157, wherein communication link V
I/OWith the coupling of control circuit in the case 17 ', or (not shown) when the control circuit in the case 17 is constructed to control a plurality of heating element and the control circuit in the case 17 be coupled.So, for example overheated if the sensor in the water tank upper 18 ' detects, then can be by the top of outlet 155, to reduce the temperature of the water that heats with a certain amount of cold water introducing water tank 11.
Fig. 6 has shown a realization water heater 160 more of the present invention.Water heater 160 is shared many common elements with water heater 10 and 150, and specifies common elements with identical Reference numeral among Fig. 1,5 and 6.For the embodiment that shows among Fig. 6, water tank 160 definition volumes 165, it has approximately last 2/3rds volume 170 and about volume 175 of 1/3rd down.Water inlet 22 is arranged in 1/3rd volumes 175 down, and cold water is introduced water tank 11.Water delivering orifice 24 is arranged in 2/3rds volumes 170.
As shown in Figure 6, heating element 16 and 16 ' all extends in 1/3rd lower volumes 175 of water tank 11.Heating element 16 and 16 ' is by the control circuit control that is stored in the control box 17, and this control circuit receives the input from temperature sensor 18 and 18 '.Perhaps, water heater 160 can comprise more than a control box, can comprise more than two heating elements, and comprise more than two temperature sensors.
Similar with disclosed water heater 150, heating element 16 and 16 ' sequentially or with certain preset frequency is started, so that heat is passed to water tank 11 with balance or consistent mode.In addition, heating element 16 and 16 ' is preferably started by the controller 17 of proportion of utilization band control technology.
In the preferred embodiment of water heater 160, heating element 16 and 16 ' is arranged in and the longitudinal axis 185 of water tank 11 (promptly in the plane of " level " basically) (see figure 7) basically in the plane orthogonal 180.Yet heating element 16 and 16 ' can place 1/3rd volumes 175 approximately down with any other structure, as long as these two elements are all getting final product (see figure 6) in 1/3rd volumes 175 approximately down.And if use extra heating element, they also are arranged in 1/3rd volumes 210 approximately down.
Typically, the water heater of prior art seldom uses the top heating element.Usually only when water heater being installed for the first time or not being used water heater for a long time or when when water tank has been extracted a large amount of hot water out, just starting the top heating element in the short time.Except these rare situations take place, seldom use the top heating element of prior art.So the most of water that heats in the life-span of unit only uses the lower element heating.Only use lower element efficient on energy low, it needs one long period that water temperature is returned to the set-point temperature, and often needs big reserve tank to guarantee can to provide enough hot water when needed.Water heater 160 has overcome above-mentioned deficiency by in 1/3rd volumes 175 approximately down that second heating element 16 ' are placed on water tank 11.Arrange element 16 and 16 ' by this way, and control operation, make water heater 160 can use more effective water heating strategy element 16 and 16 ' by the train pulse that generation has proportional band control.This causes element 16 and 16 ' that the process process of thermal energy transfer feedwater is improved, and is more effective.In addition, element 16 and 16 ' distributes watt density more equably, thereby reduces vaporization loss.So water heater 160 is compared with the conventional water heaters of prior art, have release time and use energy still less faster.In addition, compared with prior art, water heater 160 can have the compacter water tank size that is used for equal hot water needs.
Fig. 8 has illustrated and has realized another water heater 200 of the present invention.Water heater 200 comprises permanent closure water tank 205; Shell 210, it is around water tank 205; With foam-thermal insulation 210, it fills the annular space between water tank 205 and the shell 210.Water tank 205 has outside surface 206.Water inlet pipe or dip-tube 215 and rising pipe 220 enter the top of water tank 205.Water inlet pipe 215 has near the water inlet that is used for adding cold water the bottom of water tank 205.Rising pipe 220 has the water delivering orifice 230 that is used near the discharge hot water top of water tank 205.
As shown in Figure 9, controller 260 comprises cavity 267, and it has visible display area 270 and user input area 275.Visible display area 270 comprises a plurality of light emitting diodes (LED).These LED comprise the first element LED2, the second element LED3, system led 4, heating LED5, warning LED6 and power LED 7.Power LED 7 preferably red LED and the energising any time luminous (promptly " opening ").System led 4 is preferably green, and is used for total state of indication mechanism.In normal operating period, system led 4 about per seconds dodge once.The regular glittering expression water heater operate as normal of system led 4.When controller 260 is in " heating " pattern (when the instant heating hydrophone is heating water to preferred temperature), heating LED5 and system led 4 as one man glimmer.The first element LED2 and the second element LED3 are as long as just light when each heating element work.Warning LED6 and heating LED5 are in same shell.Warning LED6 and system led 4 co-operation, the state of indication water heater 200.
During normal running,, then have only system led 4 glittering if controller 260 is in " standby " pattern (that is, water temperature is equal to or higher than the expectation water temperature).If controller 260 is in heating mode, then as one man glittering system led of controller 260 4 and heating LED5.If because error condition appears in certain reason, then heat LED5 and become red alarm LED6.During error condition, the error code of system led 4 glittering misdirection types.Certainly, other LED can be increased, and arbitrary LED that discloses above can be removed or revise.In addition, can comprise the audible loudspeaker so that audible indication to be provided, perhaps the information that provides of LED can be passed on by other visual detector (as LCD).
User input area 280 comprises input dial dish 283, is used for the water temperature that the user imports expectation.Input dial dish 283 comprise close position (instant heating hydrophone 200 is " passes "), clear position and low cold water temperature is paramount or the hot water temperature between a plurality of positions.If input dial dish 285 is in clear position, then controller is in " free time " pattern." free time " pattern heats water to a preset temperature of the normal temperature range that is lower than water heater.Perhaps user input area 275 can comprise other possible equipment of the water temperature state that is used to import expectation, and it comprises having a plurality of buttons that digital LCD shows.Certainly, visible display area 275 and user input area 280 can be installed in second control box away from water heater 20 (promptly not being installed on the water heater 20).Second control box or communicate by the hardware wired connection or by RF or other suitable communication mechanism and controller 260.
As shown in figure 10, power supply 290 from the high pressure AC signal of lead 260 (Fig. 8) (for example receives, AcIn=240VAC), and (for example generate low pressure AC signal, AcOut=9VAC), unadjusted direct current (DC) signal (for example, V-SNS=5VDC) and adjusted direct current signal (for example, Vcc=5VDC).Shown example power supply 290 among Figure 11 in more detail.
As shown in figure 11, power supply 290 comprises transformer T2, and it has primary coil and the secondary coil that is used for high pressure AC signal (AcIn) is converted to low pressure AC signal (AcOut).The low pressure AC signal (AcOut) that obtains is provided for zero-crossing detector 295 (Figure 10) and switch S 1, and switch S 1 is on high-tension side single-pole single-throw (SPST) (SPST) switch that is connected to secondary coil.When switch S 1 closure, control circuit 285 work.
Power supply further comprises full wave bridge rectifier D8, capacitor C 26, Zener diode D9, pressure regulator U9 and capacitor C U1, CU2, CU4, CU7 and CU8.8 couples of low pressure AC of bridge rectifier D signal (AcOut) carries out rectification, and the signal that 26 pairs of unadjusted DC signals of capacitor C (VSNS) obtain carries out filtering.The input that Zener diode D9 cuts top and protection pressure regulator U9 to unadjusted DC signal (VSNS) avoids instantaneous short-term superpressure phenomenon.Pressure regulator U9 is with the Vcc signal of voltage-regulation to 5V, and each capacitor C U1, CU2, CU4, CU7 and CU8 on the pressure regulator U9 are the decoupling capacitors that is used for each integrated circuit.For example, capacitor C U1 is the decoupling capacitor that is used for integrated circuit U1.
With reference to Figure 10, power supply 290 provides low pressure AC signal (AcOut) to zero-crossing detector 295 again.Shown example zero-crossing detector 295 among Figure 12 in more detail.Zero-crossing detector 295 provides output signal (ZeroCross), and it indicates each detecting device 295 to detect low-voltage signal (AcOut) repeatedly to change.Zero-crossing detector 295 comprises resistance R 55, R61 and R53, capacitor C 21, diode D1 and transistor Q8.Resistance R 55 receives low pressure AC signal (AcOut).Diode D1, capacitor C 21 and resistance R 61 parallel connections, their ends are connected to the base stage of resistance R 55 and transistor Q8, and another section is connected to the emitter of transistor Q8.One end of resistance R 53 is connected to Vcc, and another section is connected to the collector of transistor Q8.Collector place of transistor Q8 generates zero cross signal (ZeroCross).Along with AC voltage changes polarity, Q8 off status and saturated between switch back and forth, thereby generate a series of pulses with forward position.The corresponding zero passage in the forward position of each pulse.
With reference to Figure 10, control circuit 285 comprises low voltage resetting circuit 300 again.The low voltage resetting circuit 300 that has shown example among Figure 13 in detail.The low voltage resetting circuit comprises integrated circuit U3, and it preferably is connected to the MotorolaMC34064P-5 (also can use other circuit) of capacitor C 18 and resistance R 45 and R46.Integrated circuit U3 provides the under-voltage reset guard signal to microcontroller U1.In the situation of power decline or " economize on electricity (brown) ", integrated circuit U3 resets microcontroller U1.Preferably, in a single day the DC signal of request is brought down below 4.5V and just carries out aforesaid operations.Low voltage resetting circuit assurance control circuit 285 is operated safely, does not break down because of lead power is low.
With reference to Figure 10, control circuit 285 comprises temperature sensing circuit 305 again.The temperature sensing circuit 305 that combines with first and second cooling- water temperature sensor 245 and 250 is transferred to microcontroller with the water temperature of water heater 200.Shown in detailed among Figure 14, temperature sensing circuit comprises resistance R 70 and R71, has the thermistor RT1 and the RT2 of negative temperature coefficient.Resistance R 70 and thermistor RT1 form first voltage divider (first sensor) that produces first temperature signal, and resistance R 71 and thermistor RT2 form second voltage divider (second sensor) that produces second temperature signal.Because first and second voltage dividers are preferably identical, so only go through first voltage divider.Along with the temperature increase of water tank 205 outsides, the resistance of thermistor RT1 descends, and causes that output voltage (first sensor) increases.Modulus among the microcontroller U1 (A/D) converter is read the voltage (first sensor) of eight digit number word.This eight digit number word is as the index of the question blank with a plurality of relevant detection temperature.According to this eight digit number word, the temperature results that obtains detecting.
Along with the water temperature in the water tank 205 raises, the error in temperature sensor 245 or 250 results that detect increases.That is it is poor, to have retardation time from water through the heat conduction via of the material of water tank 205.In order to proofread and correct it, the detected temperatures value of reading from question blank by linear equality " correction ".Microcontroller U1 uses the temperature of proofreading and correct when doing water outlet heating decision-making.
With reference to Figure 10, control circuit comprises temperature controller 310 again.Shown in detailed among Figure 15, temperature controller is potentiometer R65, and it is as voltage divider and have resistance range (as 20k ohm).The output signal of voltage divider (temperature controller) is converted to the eight digit number word by microcontroller U1, is regulated in proportion then to generate the set-point temperature value.The set-point temperature value is the temperature that water will be heated to.
With reference to Figure 10, control circuit 285 comprises LED control circuit 312 again.The startup of LED control circuit 312 control LEDs 2, LED3, LED4, LED5, LED6 and LED7.As showing in detail among Figure 16 (a) that led controller 312 comprises resistance R 56, R57, R58, R59, R60, R47, R48, R49, R50, R51 and R52 and transistor Q3, Q4, Q5, Q6 and Q7.When switch S 1 (Figure 11) when closing, power supply 290 generates the adjusted low voltage DC signal (Vcc) of supplying with LED7 and resistance R 52.The adjusted DC signal of the low pressure that provides (Vcc) is lighted LED7.In order to control LED2, LED3, LED4, LED5 and LED6, five signals are offered resistance R 56, R57, R58, R59 and R60.If arbitrary position be a height, then provide the low voltage DC signal to each resistance R 56, R57, R58, R59 or R60, make base current be enough to make electric current flow through each transistor Q3, Q4, Q5, Q6 or Q7.Electric current arrives the earth from Vcc flow through transistor Q3, Q4, Q5, Q6 or Q7 by each LED 2, LED3, LED4, LED5 or LED6.
With reference to Figure 10, control circuit comprises microcontroller or processor U1 and storage unit 315 again.Shown in Figure 16 (a), microcontroller U1 is the MotorolaMC68HC705P6A of 28 pin (also can use other microcontroller) preferably.Microcontroller U1 comprises eight input/output end ports (pin 3-10), three bit serial interface (pin 11-13), four analog to digital converters (pin 15-19), be used for the storage operation microcontroller software program storer and be used for receiving two pins (pin 26 and 27) from the signal of oscillator 317 (Figure 17).Storage unit 315 comprises electricallyerasable ROM (EEROM) (EEPROM) the chip U4 of 256 bytes.EEPROM U4 is used for store configuration data, as water heater structure and specification (for example resistance of operating voltage, water tank capacity, different elements etc.), user's use-pattern data, component type data and other related data.Had the EEPROM data and in real time sensing data (as, first and second cooling- water temperature sensors 245 and 250 temperature that detect), microcontroller U1 software program for execution is with the heating of control heating element and keep water temperature.In addition, software program comprises at least one subroutine, to determine that whether water is around each heating element.
With reference to Figure 10, control circuit comprises first driving circuit 320 and second driving circuit 325 again, and the power that provides to first and second heating elements 235 and 240 is provided respectively for they.Two driving circuits are same, so only go through driving circuit 320.Shown in Figure 16 (b), first driving circuit 320 comprises resistance R 66 and R86, TRIAC Q1 and optoacoustic coupling zero passage TRIAC driver U5.The gate pulse that TRIAC driver U5 is received by the output from microcontroller U1 determines that door drives.Train of impulses is generated by microcontroller U1, and microcontroller U1 determines to be sent to the power level of heating element 235 (Figure 10).For example, microcontroller U1 may provide train of impulses to TRIAC driver U5, causes 66% power delivery (that is, 66% available horsepower is transported to heating element); Perhaps may provide train of impulses, cause 40% power delivery to TRIAC driver U5.TRIAC driver U5 and zero-crossing detector 295 couplings are to guarantee that TRIAC turn-offs fully when reaching the set-point temperature.If do not use driver U5, then TRIAC Q1 can open by retaining part in conducted state, and influences the reliability of control circuit 285 potentially.
With reference to Figure 10, control circuit comprises dry combustion method circuit 330 again.Shown in detailed among Figure 16 (a) and 16 (b), dry combustion method circuit 330 comprises data latches U2 (16 (a)), first resistor ladder (ladder) 335 (16 (a)), second resistor ladder 340 (16 (a)), voltage sensing amplifier 345 (16 (b)), current sense amplifier 350 (16 (b)), resistance R 90, R91, R92, R97, R98 and R100 (all in 16 (b)), transistor Q9 and Q10 (all in 16 (b)), current sensor R1 (16 (b)) and resistance R 44 (16 (b)).Data latches U2 is Motorola 74HC374 data latches (can use other data latches) preferably, and it is used for preserving the five-digit number of control first and second resistor ladder 335 and 340 according to word.First resistor ladder 335 generates a voltage, voltage sensing amplifier 345 with this voltage with for referencial use.In case be provided with or calibrated this reference voltage, data latches U2 just is used to control second resistor ladder 340 and generates a voltage, and this voltage is for referencial use by current sense amplifier 350 usefulness.Latch is also preserved three extra data bit.First data bit (position 7) control shows one of LED; Second data bit (position 6) is selected EEPROM; Making it possible to carry testing tool with non-plate with the 3rd data bit (position 5) communicates by letter.Current sensor T1 and resistance R 44 generate and the proportional voltage of electric current that offers heating element.Transistor Q9 and Q10 select current which amplifier that signal is offered microcontroller U1.
The basis of " dry combustion method " test is the crest voltage on the basis of " almost " Cycle by Cycle and the measurement result of peak point current.Measurement result is not that the reason of accurate Cycle by Cycle is that voltage is to measure through rectification with after filtering.Variation in the dc voltage of the clear rectification of the change list in the AC wire voltage.Because the time constant of capacitor C 26 and the resistance in the Secondary winding of transformer, thus the voltage and current sampling be on the basis of Cycle by Cycle, carry out and be stored in the impact damper.When buffer full, check voltage sample, whether stablize to determine the time durations voltage that fills up impact damper at voltage sample.If change in acceptable limit, then the voltage and current sampling is a mean value, and carries out simple resistance calculations (being R=V/I).
When producer's assembled heat hydrophone 200, the producer will be used for assembled heat hydrophone 200 member, water tank 205 volume and/or about the product information programming write storage unit 315 of the particular element of water heater 200.For example, the producer can be with one or more water tank characteristics and/or one or more element characteristic programming write storage unit.The water tank characteristic can include but not limited to water tank diameter, water tank height, water tank storage volume etc.Thermal convection mode in the water tank 205 of water tank characteristic decision generation different temperatures water layer in water tank 205.Element characteristic can include but not limited to the physical location (as top or bottom or parallel (side-by-side)), element watt density of parts number, component type, element voltage, element etc.Element characteristic helps to provide the information that how to add hot water about element 235 and 240 effectively.
In addition, microcontroller U1 can determine some water tanks or element characteristic.For example, microcontroller can be by the component resistance after applying voltage to element and calculating a period of time, and is specific element computing element power.
Preferably, all water-heater water tank characteristics and element characteristic are all programmed write storage unit 315.According to variable and characteristic, microcontroller U1 obtains from question blank specific to the code of water heater 200.The software section of microcontroller U1 is that water heater 200 generates heating strategy (following discussion) according to the water heater code.If microcontroller U1 detects element and is replaced, or the data reprogramming of maintainer to storing in the storage unit 315, then microcontroller U1 can upgrade the water heater code.In addition, although the producer can envision each variable or characteristic programming write storage unit 315, the producer can directly go into code programming storage unit 315.
Because in the manufacturing of electric heater and structure, used multiple water tank characteristic and element, so only depend on heating strategy can not solve numerous structures.And software according to the variable of water heater 200 and characteristic to water heater 200 appointment codes.Variable and characteristic have defined the signature of water heater, and when using with the water heater use-pattern, variable and characteristic generate more reliable effective and energy-conservation water heater.
With reference now to Figure 18,, in the operation of water heater 200, the user is by turning clockwise temperature controller 310 and " opening " water heater 200 (steps 500) from closing the position.This has closed switch S 1.In case off switch S1, power supply 290 just generate low pressure AC signal (AcOut), unrectified DC signal (V-SNS) and rectified DC signal (Vcc).In case power supply generates the Vcc that is higher than 4.5V, low voltage resetting 300 is taken microcontroller U1 out of reset mode.If whenever voltage is brought down below 4.5V (for example, user's shutdown system, generation " outage " or generation " economize on electricity "), then low voltage resetting 300 provides signal to microcontroller U1, and microcontroller U1 resets.
In step 505, after microcontroller U1 comes out from reset, software initialization microcontroller U1.Software is reset to their default value with all variablees, and all outputs are reset to their default conditions separately.
In step 510, microcontroller is carried out " dry combustion method " test.Term " dry combustion method " is meant that the heating element 235 or 240 to not immersing water heats.Usually, " dry combustion method " will within one minute, destroy or burn out heating element 235 or 240.Control circuit 285 is carried out " dry combustion method " test, to determine whether heating element is centered on by water.
Usually, control circuit 285 put on by measurement heating element 235 and 240 each peak point current and crest voltage and carry out resistance calculations according to measurement result, carry out " dry combustion method " test.For example, by applying the voltage of special time length to one of heating element 235 or 240, and, can determine the state of heating element 235 or 240 at starting point and the terminal point measuring resistance of test period.Along with element 235 or 240 heating, its resistance increases.If element is in water, then element reaches balance (promptly stable temperature and resistance) very soon.On the contrary, if element 235 or 240 is " doing ", then its continues heating and at very short time reach a high temperature (and high resistance).When end of test (EOT), compare starting point and terminal point resistance.For " wetting " element, the difference of starting point and terminal point resistance is little; And for " doing " element, the big manyfold of the difference specific humidity element of starting point and terminal point resistance.
In addition, by changing the length of dry combustion method test, can accurately measure the watt density of heating element 235 or 240.According to watt density, microcontroller U1 can upgrade the water heater code.
Figure 19 has shown a kind of exemplary method that is used to carry out the dry combustion method test.In step 605, microcontroller U1 is invalid at dry combustion method testing period all LED of chien shih.The flicker of the invalid assurance LED of LED does not influence test.In step 610, software setting element number, this element number indicate first heating element 235 testing.In step 615, the operator scheme of software microcontroller U1 is set to the dry combustion method pattern, and it is carrying out the dry combustion method test to all subroutine notice microcontroller U1.In step 620, software is removed all dry combustion method error flags.Whether the nearest dry combustion method test (if generation) of dry combustion method error flag indication leads to errors.For example, if preceding dry combustion method test cause being " doing " corresponding to the error flag of first element, microcontroller U1 reset circuit sign then then, the result that Pretesting is worked as in its expression does not also finish.
In step 625, microcontroller U1 calibration voltage amplifier 345.Before arbitrary voltage sample can be used as dry combustion method calculating use, must use the variable reference voltage calibration voltage amplifier 345 that generates by data latches U2 and resistor ladder 335.In order to finish this calibration, microcontroller U1 at first enters saturated (Q9 is for closing) by ordering about Q10, selects the output of voltage sensing circuit.Then reference voltage (V-REF) is set to its mxm..Next, reference voltage (V-REF) little by little reduces, and reaches predetermined value until the output (Dry-Out) of voltage amplifier.So reference voltage is stayed this value.
For example, V-SNS is unregulated DC signal, and it has steady state element and little " alternating current " element.Any increase in offering the signal of transformer (AcIn) or reduce and in little " AC " of V-SNS signal element, to be embodied.In order to make microcontroller U1 notice any important variation, voltage amplifier 345 amplifies the variation of little " AC " element.For example, if stable state is 2.0V, any reference voltage (V-REF) that surpasses 2.0V that then flows into resistance R 88 (Figure 16 (b)) will cause not taking place to amplify and the output of amplifier will be zero.If reference voltage (V-REF) is lower than 2.0V, then will amplify.Adjust reference voltage (V-REF), so the output of U7B is in its output amplitude (for example, middle somewhere 0-3.5V).Microcontroller U1 continues to reduce reference voltage (V-REF) with acting in agreement, until the output that reaches expectation (for example, reference voltage equals 1.5V).So the factor that any variation in the wire voltage is equated with the gain of U7B is amplified.
In step 630, microcontroller U1 calibration current amplifier 350.Owing to have voltage amplifier 345, subordinate phase must can begin to calibrate U8B (Figure 16 (b)) before the sampling.Enter saturated (Q10 pass) and regulate reference current (I-REF) similarly gradually with reference voltage (V-REF) then by ordering about Q9, select current sense circuit.
In step 635, software determines whether voltage and current amplifier 345 and 350 is correctly calibrated.If wrong in calibration, then software is calibrated error flag and is set to positive result (step 640), and enters step 660.If calibration is without any mistake, then microcontroller U1 enters step 645.
In step 645, microcontroller U1 carries out the dry combustion method test to first element 235.For this test, measure instantaneous voltage and electric current at the peak value place.This is to finish by the signal of the voltage and current of amplifying circuit 345 and 350 (Dry-Out) is sampled with respect to the zero passage of low pressure AC signal (AcOut).At suitable zero passage place, start timer for each amplifying circuit 340 and 350.When the voltage and current waveform is in peak value, use overtime variable to come to carry out voltage or current sample with respect to zero passage with the predetermined cycle.Instantaneous voltage and current sample are loaded into separately and divide other impact damper among the microcontroller U1.When buffer full, analyze data to determine whether wire voltage is stable during the sampling period.If sampled voltage is stable, then calculates average voltage and electric current, and carry out resistance calculations.Continuing this mode at the dry combustion method test period calculates.At the test end, extract starting point and terminal point resistance value, with found out in test process resistance variations what.The basis of test is not the actual value (different with each type of heating element) of resistance, but the difference of resistance from the test starting point to the test terminal point.
In step 650, microcontroller U1 determines whether first element 235 is dried.If the resistance difference that calculates is greater than being provided with increased resistance value (this can change according to the heating element that uses), then microcontroller U1 determines that this element is not surrounded (that is, " doing ") and enters step 655 by water.If the definite resistance variations of calculating of microcontroller U1 is equal to or less than increased resistance value is set, then microcontroller U1 determines that this element is surrounded and enter step 660 by water.
In step 655, the software first element error flag is set to positive result.The first positive element error flag notifies first element 235 not surrounded by water to subroutine subsequently.Therefore, the subroutine of back will not use this element to add hot water.Microcontroller U1 also is set to 180 minutes to the ReCheck timer.The ReCheck timer will successively decrease in time, until reaching zero minutes.When the ReCheck timer reaches zero, microcontroller U1 will carry out another dry combustion method test on this element.
In step 660, microcontroller U1 element number is set to second element.Whether in step 665, microcontroller U1 is the second element repeating step 625,630,635,640,645,650 and 655, do to determine second element.If microcontroller U2 determines second element and does that then it is set to positive result to the second element error flag.Certainly, if water heater comprises that more than two heating elements then microcontroller U2 carries out for all the other elements and does test.In addition, if water heater only comprises a heating element, then microcontroller U2 incites somebody to action not execution in step 660 or 665.
With reference to Figure 18, in step 515, software determines that " ReCheck " is overtime whether greater than zero again.ReCheck is overtime to be the timer (for example 20ms) that is used by software, is used for notifying software in the time will sampling to temperature sensor 245,250 and 255, and generates or revise the heating strategy that heat packs is contained in the water in the water heater.If ReCheck is overtime greater than zero, then software enters step 520.Be less than or equal to zero if ReCheck is overtime, then software enters step 525.
In step 520, microcontroller U1 " lights " system led 4, heating LED5 and warning LED6.That is, software is according to the residing pattern of software or error flag has not taken place, and carries out the subroutine that starts suitable LED.For example, during normal running, microcontroller 305 generates the signal that makes that system led 4 is glittering or extinguish.If software is in heating mode (following discussion), then heat LED5 and system led 4 is as one man glittering.If software has positive error flag, the state of water heater 200 is indicated in then report to the police LED6 and system led 4 actings in conjunction to operator or maintenance personal.
Be less than or equal to zero if ReCheck is overtime, then microcontroller U1 enters step 525.Usually, microcontroller U1 sample temperature sensor samples (step 525), calculate water temperature (step 530), calculate temperature controller setting (step 535), set up operator scheme (step 540), heat cycles state (step 545) is set and heating priority (step 550) is set.The exemplary method that has shown performing step 525,530,535,540,545 and 550 among Figure 18.In addition, microcontroller U1 storage is used to generate the data (step 555) of using history and light LED (step 560).
At step 705 (Figure 20 (a)), microcontroller U1 samples to temperature sensor 245 and first voltage that will obtain is written into and is used in the software handling.In step 710, microcontroller U1 samples to temperature sensor 250 and second voltage that will obtain is written into and is used in the software handling.In step 715, microcontroller U1 serviceability temperature question blank is converted to first and second sensing temperatures respectively with first and second sampled voltages.Question blank comprises a plurality of voltage ranges with each associated temperature.For example, if first temperature sensor generates the 2.1V signal, then Xiang Guan temperature may be 110 °F.Question blank can change according to the sensor that uses.After obtaining first and second detected temperatures, any time delay of software consideration when obtaining temperature, revise the temperature that detects.That is,, increase progressively error so in temperature sensor 245 or 250 results that detect, exist because the water temperature in the water tank 205 raises.Has difference time delay from the heat conduction via of water by the material of water tank 205.In order to proofread and correct it, the temperature value that this delay is read " correction " from question blank.Do to use the first and second calibrated temperature in the water outlet heating decision at software.
In step 720, microcontroller U1 loads or samples from the signal of temperature controller 310.If microcontroller U1 determines temperature controller voltage correspondence and is in the temperature controller (step 725) that off-position is put, the software operator scheme step 555 that is set to equal off status (step 730) and returns Figure 18 then.For example, if temperature controller voltage is lower than 0.1V, then software determines that temperature controller is in the position, pass, and turn-offs controller 260.If temperature controller voltage is greater than the voltage (step 725) corresponding to the position, pass, then software enters step 735.
In step 735, software determines whether operator scheme before had been set to close (that is, system just opens).If operator scheme before had been to close, then software is changed into operator scheme " standby " (step 740).As what below will go through, when water heater 200 was in standby mode, controller 260 did not increase water temperature.Close operator scheme pattern in addition if operator scheme is in, then software enters step 745.
In step 745, software with temperature controller voltage with represent temperature controller clear position voltage ratio is set.For example, if temperature controller voltage less than 0.7V, then software determines that temperature controller is set to clear position and enters step 750.If temperature controller voltage is greater than 0.7V, then software determine the user water heater be set to desired temperatures, and enter step 755.
In step 750, software set-point temperature is set to equal idle temperature (for example, 90).Idle temperature can be the value determined of manufacturer or by user preset.After being provided with the set-point temperature, software enters step 760 (Figure 20 (b)).
At step 755 (Figure 20 (b)), software is according to the temperature controller voltage of sampling, calculating and setting point temperature.Microcontroller U1 preferably uses second question blank, but also can use the formula based on input voltage.
In step 760, the computed in software water heater is opened temperature.It is the temperature that one or more elements receive power signal that water heater is opened temperature.It is that the set-point temperature deducts temperature hysteresis that water heater is opened temperature.Temperature hysteresis is water temperature deg. F. (for example, 10 degrees Fahrenheits) lower than set-point temperature before heating.So, opening temperature by calculating water heater, microcontroller U1 avoids " owing circulation (under cycling) ".
In step 765, software determines whether operator scheme is in " standby " pattern or " heating " pattern.If operator scheme is set as standby, then software enters step 770.If operator scheme is set as heating, then software enters step 775.
In step 770, software determines whether water tank temperature of lower (from temperature sensor 250) is less than or equal to water heater and opens temperature.Open temperature if the water tank temperature of lower is less than or equal to water heater, then software is determined and should and be entered step 780 with the water heating.Open temperature if the water tank temperature of lower is higher than water heater, then software is determined should not heat water, and enters step 800.
In step 780, the software operator scheme is set to heating mode, and indication should be heated water.After operator scheme was set to heating, software was for another heat cycles reset all operations state variable and overtime (step 785).For example, software reset ReCheck overtime (for example 20ms).
If in step 765, software determines that operator scheme is set to heating, and then software enters step 775.In step 775, software determines whether the water tank temperature of lower is greater than or equal to the set-point temperature.If the water tank temperature of lower is greater than or equal to the set-point temperature, then software is determined should continue water is heated, and therefore rests in the heating mode, and enters step 800.If the water tank temperature of lower is less than the set-point temperature, then software determines that water is heated suitably, and enters step 785.
In step 785, software changes to standby (that is, indicating water temperature should not increase again) with operator scheme.In step 790, software determines whether first heating element 235 is surrounded (supposing that first element is on second element) by water.If first heating element 235 is not surrounded (that is, element is for doing) by water, then the overtime variable of software ReCheck is set to two minutes (step 795).By changing the length of the overtime variable of ReCheck, software makes water tank can be full of water before by the heating of first element.Certainly, the time quantum of the overtime variable of ReCheck of software setting can change, and does not need specific value for the purposes of the invention that will work.If first element is surrounded (that is, obtaining wet condition) by water really, then software enters step 800.
At step 800 (Figure 20 (c)), software determines whether to have passed through the temperature slope computation period.Should cycle, then software reset's timer and accounting temperature slope (step 805) if passed through.The accounting temperature slope makes and can determine whether drawing water.Nearest water tank temperature sampling compares with the previous sample of storage in the time interval (for example, 90 seconds) the same storage unit (315) of routine.According to temperature value, to the speed of water accounting temperature slope or temperature variation.If the user is drawing water, then will obtain big negative slope value, water is drawn to the software notice.
In step 810, the software setting working cycle, it determines to pass to the electric weight of each heating element.Electric weight changes according to the water heater code of water temperature and water heater 200.In addition, electric weight can be considered water heater use-pattern (it is stored in the storage unit 315), environment temperature, water uniformity coefficient value or out of Memory.
For step 810, software obtains the past data record of water heater code and water heater storage from storage unit 315.During each software end step 555 (Figure 18), storage record in the past, and every record comprise time on date, past the duration of heat, water temperature reduce and rising in rate of change (slope), also may comprise out of Memory, as environment temperature.When 260 pairs of water of controller heated, it searched for sky and/or the recorded information of similar situation during the identical time period in week before in storage unit 315.If show the user uses about equivalent during arbitrary preset time water, then water will be heated by the standard speed with the water heater code, and this speed will satisfy the expectation consumption of the water of heating.If the data indication of storage no longer includes use after current heat cycles, then will very lentamente water be heated, with energy consumption minimized with lower working cycle.Descend (that is, negative temperature slope) if having in water temperature suddenly or rapidly, then software will calculate new working cycle according to the current service condition of water heater.Along with use-pattern changes, change old record to reflect current operating conditions.For preferred embodiment, consider that what minimum water temperature flow velocity will be that acceptable baseline formula is a minimum restoring, it equals with 60 risings per hour ten gallons.
With this formula, product code information and service recorder, change relative power input than being used to determine heating strategy with temperature speed.This strategy provides input power level, to meet or exceed minimum restoring speed, simultaneously energy efficiency is remained maximum.Along with the condition in the use-pattern changes, improvement strategy is to keep minimum recovery standard.
For example, being used to have the standard heating strategy of the first water heater code of first element power will be different with the heating strategy of the second water heater code that is used to have second element power.Two kinds of exemplary heating strategies have been shown in the table 1 and 2 for second element 240.
Table 1: for the water heating strategy of primary heater code
Water temperature
The power of second element or working cycle
＜115°F 100％
115°F～120°F 66％
120°F～125°F 57％
125°F～130°F 50％
130°F～135°F 40％
135°F＞ 20％
Table 2: for the water heating strategy of secondary heater code
Water temperature
The power of second element or working cycle
＜115°F 100％
115°F～120°F 80％
120°F～125°F 66％
125°F～130°F 50％
130°F～135°F 40％
135°F＞ 20％
For water heater 200, put on the working cycle of heating element 235 or 240 or power to small part based on the water temperature and the water heater code that detect.The notion of heating strategy that depends on the water heater code is unlike the method that adds hot water for water heater 10 and 150.For water heater 10 and 150, put on poor between the water temperature of working cycle of heating element 16 and/or 16 ' or water temperature that power is based on detection and expectation.Yet determine, compare, in given water temperature power is increased to water-immersed element and may not can causes optimum water temperature gain with the power input.For example, suppose that all other conditions all are identical, can determine, when water is in cool temperature, can be more hot to the water transmission from element.Along with water temperature raises, the power that need offer heating element 235 or 240 is less, and and the difference between measurement temperature and the preferred temperature irrelevant (that is, compare with the power input, the power that exceeds the quata will can not cause best transmission).Therefore, software need not to consider preferred temperature and measure poor between the temperature for water is heated.But can envision, (for example, use-pattern changes, and needs water to be heated as early as possible, and need not to consider efficient) heating strategy may need to comprise the difference measurement result under some conditions.
In step 815, software is determined " drawing decline (draw down) " state.The user is current whether is drawing water, and the user just draws water with what speed for draw state indication.Draw the decline state four values are arranged: " water tank is in heating ", " drawing decline-1 ", " drawing decline-2 " and " recovery ".If draw the decline state is " water tank is in heating ", and then software enters step 820.If drawing the decline state is " drawing decline-1 ", then software enters step 825.If drawing the decline state is " recovery ", then software enters step 830.If the diversion state is " drawing decline-2 ", then software enters step 835.
In step 820, software determines whether temperature slope is less than or equal to the threshold value of drawing decline.For example, if the temperature slope that calculates less than 10 °F, then software is determined is drawing decline, and draws the decline state and be set to " drawing decline-1 " (step 840).If temperature slope is greater than drawing falling-threshold value, then software is determined do not drawing, and enters step 870.
If drawing the decline state current is " drawing decline-1 ", then is in before the water heater and draws decline (that is, the user is using hot water).In step 825, software determines that temperature slope is whether for just.If temperature slope is for just, then software determines that water heater recovers, and draws the decline state and be set to recover (step 845).If temperature slope is still for negative, then software is determined that water heater still is in and is drawn decline, and enters step 870.
The decline state is current to be set to " recovery " if draw, and then water heater recovers from draw decline.In step 830, software determines whether to exist another to draw decline (that is, temperature slope is less than or equal to the threshold value of drawing decline).If there is another to draw decline, then software draws the decline state and is set to " drawing decline-2 " (step 850).If software is determined water heater and is still recovering that then program enters step 870.
In step 835, software determines whether the water tank temperature of lower opens temperature more than or equal to water heater.If the water tank temperature of lower is left temperature more than or equal to water heater, then software draws the decline state and is set to recovery and reset temperature slope.If the water tank temperature of lower is left temperature less than water heater, then microcontroller U1 working cycle is set to full power (step 760).Certainly, depend on specific water heater and ambient conditions, can use other working cycle.
In step 870, software is that water heater is determined heating priority.If heating priority is " 50 pairs 50 " (following discussion), then software and water temperature irrespectively working cycle be set to full power (step 875).Certainly, depend on specific water heater and ambient conditions, can use other working cycle.If heating priority is not 50 pairs 50 patterns, then software enters step 880 (Figure 20 (d)).
In step 880, software is selected a situation according to the previous heating priority of determining.Which element is heating priority be used for determining to start.For example, if first element is the element on top, and second element is the element (similar to Fig. 5) of bottom, and then under certain condition, two elements can use.For this arrangement, if two elements all just are used, then heating priority will be divided equally.If only used an element, then heating priority is 0 pair 100.Perhaps, if in substantially horizontal plane, then can being 50 pairs 50 arrangement, element use two elements (comparing) to come water is heated with only using an element.
In step 885, software determines whether the water tank temperature on top descends (that is, the temperature slope of upper element is less than or equal to threshold value).If the upper tank temperature has descended, then the software heating priority is set to " 50 pairs 50 " (step 887), makes two elements all heat water.If the upper tank temperature does not descend, then software enters step 555 (Figure 16).
In step 890, software determines whether the upper tank temperature is recovered (that is, the temperature slope of upper element is greater than threshold value).If the upper temp water tank recovers, then software priority is set to " 0 pair 100 " (step 895), makes that only 240 pairs of water of second element heat.If the upper tank temperature is not recovered, then software enters step 555 (Figure 16).
The every 800ms of software carries out a timer interrupt event.Timer interrupts the timing benchmark as multiple overtime (for example, " ReCheck " is overtime).At each intercourse, the timer of microcontroller is reset, and if the value of overtime variable still greater than zero then reduce overtime variable.In case timeout value reaches zero, then can at this moment or during major cycle, carry out relevant subroutine.As shown in figure 21, be next predetermined interruption reset condition timer at step 905 software.In step 910, software is overtime service (that is, reduce each overtime) and lagged variable.In step 915, software is carried out the subroutine relevant with incident as required.In step 920, software is from interrupting being back to the step of previous execution.
Each signal (AcOuhHI) is when crossing 0V, and microcontroller U1 carries out the zero passage event interrupt.As transistor Q8 (Figure 12) when opening, it enters saturated, causes the negative edge of the interruption that generates microcontroller U1.This negative edge is with acting on the reference edge that starts TRIAC Q1 and Q2 (Figure 16 (b)).When taking place, regulate timer and interrupt (Figure 21), so that time of its accurately corresponding generation zero passage with reference to the edge.In this way, zero passage interrupts accurately starting TRIAC in orthochronous.
In order to control the power that passes to heating element 235 and 240, microcontroller U1 generates output signal (first element or second element), and this output signal is supplied with zero passage TRIAC driver U5 and U6 respectively.Zero passage TRIAC driver U5 and U6 and TRIAC Q1 and Q2 jointly control the high pressure AC signal (AcIn) that offers heating element 235 and 240.
In order to control the power that passes to heating element 235 and 240,, start TRIAC Q1 or Q2 for the sequence in four half continuous AC cycles.TRIAC Q1 that starts or Q2 are based on the state of heating priority and the software relevant with heat cycles.For example, if heating priority is " 0 a pair 100 ", then only start a TRIAC Q2.Perhaps, if heating priority be " 50 pairs 50 " and heating element 235 and 240 by sequence starting, then software comprises which the variable of determining to start heating element 235 or 240.After the sequence that starts four order AC semiperiods, software delays starts, and does not promptly start TRIAC Q1 or Q2 in many cycles.The periodicity that does not start TRIAC Q1 or Q2 is determined by the performance number that will pass to heating element 235 or 240.For example, if transmit 100% power, then software will be fully delay start not.If transmit 50% power, then software will be in the four and half AC cycles of start delay of TRIAC Q1 or Q2.Table 3 has disclosed exemplary electric power transition table.
Table 3: be used for question blank based on the multiple working cycle phase of phase startup around initial
Postpone (semiperiod)
Power transmits
0 semiperiod postponed 100% power
1 semiperiod postponed 80% power
2 semiperiods postponed 66% power
3 semiperiods postponed 57% power
4 semiperiods postponed 50% power
6 semiperiods postponed 40% power
16 semiperiods postponed 20% power
Certainly, can use other semiperiod to postpone, and can change the initial startup of phase all around, to obtain different power transmission ratios.
Although show here and described specific embodiment of the present invention, under the premise without departing from the spirit and scope of the present invention, can make and change and revise.For example, can use the logic chip that is different from Motorola UAA1016A logic chip to control the switch circulation of thyristor 103.And, can use the temperature sensing device that is different from thermistor as temperature sensing device 102.And, can use the thyristor that is different from Motorola TRIAC as thyristor 103, and can use multiple heating element above-mentioned and other selectable control circuit.Therefore, the qualification that in claims, comprises, there is not other limitation of the invention.
Various further feature of the present invention and advantage have been proposed in the claim below.
Claims (84)
1. method of controlling the water temperature in the water heater, wherein water heater comprises the water tank that is used for water storage and can be by the heating element of power supply power supply, this method may further comprise the steps:
Determine the element characteristic of heating element;
Detect the water temperature in the water tank;
To small part based on element characteristic and water temperature, calculating will offer the performance number of heating element; And
With performance number from power delivery to heating element.
2. method as claimed in claim 1, wherein element characteristic comprises component type.
3. method as claimed in claim 1, wherein element characteristic comprises element power.
4. method as claimed in claim 1, wherein element characteristic comprises element voltage.
5. method as claimed in claim 1, wherein element characteristic comprises the position of element in water tank.
6. method as claimed in claim 1, wherein further comprise can be by second heating element of power supply power supply for water heater, and this method further may further comprise the steps:
Determine second element characteristic of second heating element;
To small part based on second element characteristic and water temperature, calculating will offer the performance number of second heating element; And
With performance number from power delivery to the second heating element.
7. method as claimed in claim 6, the step of wherein calculating first performance number to small part based on second element characteristic, and the step of calculating second performance number to small part based on first element characteristic.
8. method as claimed in claim 1 further comprises:
Determine the water tank characteristic of water tank; And
Wherein the step of calculated power value to small part based on the water tank characteristic.
9. method as claimed in claim 8, wherein the water tank characteristic comprises water tank capacity.
10. method as claimed in claim 8, wherein the water tank characteristic comprises around water tank diameter, water tank radius, the water tank or the water tank area of section.
11. method as claimed in claim 8, wherein the water tank characteristic comprises the water tank height.
12. method as claimed in claim 1 further comprises:
Detect second temperature of the water in the water tank; And
Wherein the step of calculated power value to small part based on second temperature.
13. as the method for claim 12, wherein first temperature is detected by first sensor, and second temperature is by second sensor.
14. as the method for claim 12, wherein second temperature detects after first temperature.
15. the method as claim 14 further comprises:
To small part based on first and second temperature, calculate the slope of line; And
Wherein the step of calculated power value is to the slope of small part based on calculating.
16. method as claimed in claim 1 further comprises:
The step of duplicate detection water temperature;
Store the temperature of each detection, this storing step causes a use-pattern; And
Wherein the step of calculated power value to small part based on this use-pattern.
17. method as claimed in claim 1, wherein the step of through-put power comprises:
With train of impulses with power from power delivery to heating element.
18. method as claimed in claim 6, wherein comprise with first train of impulses power from power delivery to the first heating element to the step of the first element transmission power, and comprise with second train of impulses power from power delivery to the second heating element to the step of the second element transmission power from power supply from power supply.
19. as the method for claim 18, wherein with second train of impulses with power from the step of power delivery to the second element with first train of impulses with power after the step of power delivery to the first heating element.
20. method as claimed in claim 1 further may further comprise the steps:
The testing environment temperature; And
Wherein the step of calculated power value to small part based on environment temperature.
21. method as claimed in claim 3 determines that wherein the step of element characteristic may further comprise the steps:
With voltage transmission to heating element; And
Calculate the element power of heating element.
22. as the method for claim 11, wherein the step of calculated power value may further comprise the steps:
Storage unit is provided, and it has and comprises a plurality of water heater codes and separately the table that adds dsc data;
To small part based on element characteristic, create the first water heater code;
Respond the first water heater code, from described table, obtain adding dsc data; And
To the temperature of small part based on the first water heater code and detection, calculated power value.
23. a method of controlling the water temperature in the water heater, wherein water heater comprises the water tank that is used for water storage and can be by the heating element of power supply power supply, and this method may further comprise the steps:
Determine the water tank characteristic of water tank;
Detect the water temperature in the water tank;
To small part based on water tank characteristic and water temperature, calculating will offer the performance number of heating element; And
With performance number from power delivery to heating element.
24. as the method for claim 23, wherein the water tank characteristic comprises water tank capacity.
25. as the method for claim 23, wherein the water tank characteristic comprises around water tank diameter, water tank radius, the water tank or the water tank area of section.
26. as the method for claim 23, wherein the water tank characteristic comprises the water tank height.
27. as the method for claim 23, wherein the step of calculated power value may further comprise the steps:
Storage unit is provided, and it has and comprises a plurality of water heater codes and separately the table that adds dsc data;
To small part based on the water tank characteristic, create the first water heater code;
Respond the first water heater code, from described table, obtain adding dsc data; And
To the temperature of small part based on the first water heater code and detection, calculated power value.
28. a method of controlling the water temperature in the water heater, wherein water heater comprises the water tank that is used for water storage and can be by the heating element of power supply power supply, and this method may further comprise the steps:
Detect the environment temperature of water heater outside;
Detect the water temperature in the water tank;
To small part based on environment temperature and water temperature, calculating will offer the performance number of heating element; And
With performance number from power delivery to heating element.
29. the method as claim 28 further may further comprise the steps:
Determine the element characteristic of heating element; And
Wherein the step of calculated power value to small part based on element characteristic.
30. the method as claim 28 further may further comprise the steps:
Determine the water tank characteristic of water tank; And
Wherein the step of calculated power value to small part based on the water tank characteristic.
31. the method as claim 28 further comprises:
Detect second temperature of the water in the water tank; And
Wherein the step of calculated power value to small part based on second temperature.
32. as the method for claim 31, wherein first temperature is detected by first sensor, and second temperature is by second sensor.
33. as the method for claim 31, wherein second temperature detects after first temperature.
34. the method as claim 33 further comprises:
To small part based on first and second temperature, calculate the slope of line; And
Wherein the step of calculated power value is to the slope of small part based on calculating.
35. the method as claim 28 further comprises:
The step of duplicate detection environment temperature;
Store the temperature of each detection, this storing step causes a use-pattern; And
Wherein the step of calculated power value to small part based on this use-pattern.
36. the method as claim 35 further comprises:
The step of duplicate detection water temperature;
Store the environment temperature of each detection.
37. as the method for claim 28, wherein the step of through-put power comprises with train of impulses power from power delivery to heating element.
38. one kind is used to generate and causes performance number to be transferred to the software program of the signal of heating element, wherein heating element places within the water tank that comprises liquid, and liquid has the temperature that is detected by temperature sensor, and this software program generates described signal by following steps:
Obtain the water heater code from storage unit, this water heater code to small part based on one of heating element characteristic and water tank characteristic;
Receive the temperature of liquid from temperature sensor;
To the temperature of small part based on water heater code and detection, calculating will transfer to the performance number of heating element; And
Generation causes performance number to be provided for the signal of heating element.
39. as the software program of claim 38, wherein the water heater code to small part based on element characteristic and water tank characteristic.
40. as the software program of claim 38, wherein element characteristic comprises component type.
41. as the software program of claim 38, wherein element characteristic comprises element power.
42. as the software program of claim 38, wherein element characteristic comprises element voltage.
43. as the software program of claim 38, wherein element characteristic comprises the position of element in water tank.
44. as the software program of claim 38, wherein further comprise can be by second heating element of power supply power supply for water heater, and the water heater code to small part based on the second heating element characteristic.
45. the software program as claim 44 further may further comprise the steps:
To the temperature of small part based on water heater code and detection, calculating will transfer to second performance number of second heating element; And
Generation causes second performance number to be provided for the secondary signal of second heating element.
46. as the software program of claim 38, wherein the water tank characteristic comprises water tank capacity.
47. as the software program of claim 38, wherein the water tank characteristic comprises around water tank diameter, water tank radius, the water tank or the water tank area of section.
48. as the software program of claim 38, wherein the water tank characteristic comprises the water tank height.
49. the software program as claim 38 further comprises:
Detect second temperature of the liquid in the water tank; And
Wherein the step of calculated power value to small part based on second temperature.
50. as the software program of claim 49, wherein second temperature is by second sensor.
51. as the software program of claim 49, wherein second temperature detects after first temperature.
52. the software program as claim 51 further comprises:
To small part based on first and second temperature, calculate the slope of line; And
Wherein the step of calculated power value is to the slope of small part based on calculating.
53. the software program as claim 38 further comprises:
The step of duplicate detection water temperature;
Store the temperature of each detection, this storing step causes a use-pattern; And
Wherein the step of calculated power value to small part based on this water use model.
54. as the software program of claim 38, the step that wherein generates signal comprises:
Generation causes performance number to be transferred into the signal of heating element with train of impulses, and this train of impulses heel is not with to time period of heating element delivering power.
55. as the software program of claim 45, the step that wherein generates first signal comprises:
Generation causes first performance number to be transferred into first signal of first heating element with first train of impulses, and this first train of impulses heel is not with to time period of the first heating element delivering power; And
The step that wherein generates secondary signal comprises:
Generation causes second performance number to be transferred into the secondary signal of second heating element with second train of impulses, and this second train of impulses heel is not with to time period of second heating element supply power.
56. as the software program of claim 55, the step that wherein generates secondary signal is after the step that generates first signal.
57. the software program as claim 38 further may further comprise the steps:
The testing environment temperature; And
Wherein the step of calculated power value to small part based on environment temperature.
58. a water heater comprises:
Water tank, it has the water tank characteristic;
Water inlet pipe is used for cold water is introduced water tank;
Rising pipe, it can be discharged hot water from water tank;
Heating element, it has the area of heating surface that is positioned at water tank and has element characteristic;
Temperature sensor, it can detect the water temperature in the water tank; With
Controller, itself and heating element and temperature sensor communicate, can operate this controller to receive temperature from the detection of temperature sensor, so that small part is calculated the heating strategy of water heater based on one of element characteristic and water tank characteristic, and respond the signal that heating strategy generates the startup heating element.
59. as the water heater of claim 58, wherein heating strategy to small part based on element characteristic and water tank characteristic.
60. as the water heater of claim 58, wherein element characteristic comprises component type.
61. as the water heater of claim 58, wherein element characteristic comprises element power.
62. as the water heater of claim 58, wherein element characteristic comprises element voltage.
63. as the water heater of claim 58, wherein element characteristic comprises the position of element in water tank.
64. as the water heater of claim 58, wherein the water tank characteristic comprises water tank capacity.
65. as the water heater of claim 58, wherein the water tank characteristic comprises around water tank diameter, water tank radius, the water tank or the water tank area of section.
66. as the water heater of claim 58, wherein the water tank characteristic comprises the water tank height.
67. the water heater as claim 58 further comprises:
Second heating element, it has and places second area of heating surface in the water tank and have second element characteristic; With
Its middle controller and heating element communicate, and can operate this controller so that small part is calculated the heating strategy of water heater based on second element characteristic, and respond the signal that heating strategy generates startup second heating element.
68. water heater as claim 58, wherein can operation control with control with the electric power supply of train of impulses to first and second heating elements, all follow not time period behind each train of impulses to the heating element supplied with electric power, further can operation control circuit starting first heating element or very first time section, and second heating element was started for second time period.
69., wherein after starting first heating element, start second heating element as the water heater of claim 59.
70. as the water heater of claim 59, wherein first and second time periods changed according to heating strategy.
71. a storage-type water heater comprises:
The permanent closure water tank is used for storage of water during water is heated to the set-point temperature;
Water inlet pipe is used for adding cold water to water tank;
Rising pipe is used for discharging the water that process heats from water tank;
At least one stratie, it extends into water tank with the water in the heating water tank;
At least one cooling-water temperature sensor, it can be operated and be used for detecting water temperature; With
Control circuit, it can be operated to train of impulses electric power be conducted to stratie, all follow not time period behind each train of impulses to the stratie conduct electrical power, thereby improved the efficient of the water in the heating water tank, and at least one item changes dutycycle in the water temperature that can operation control circuit detects with response and element characteristic, water tank characteristic, water tank external temperature, water uniformity coefficient and the water history.
72. as the water heater of claim 71, wherein element characteristic comprises component type.
73. as the water heater of claim 71, wherein element characteristic comprises element power.
74. as the water heater of claim 71, wherein element characteristic comprises element voltage.
75. as the water heater of claim 71, wherein element characteristic comprises the position of element in water tank.
76. as the water heater of claim 71, wherein the water tank characteristic comprises water tank capacity.
77. as the water heater of claim 71, wherein the water tank characteristic comprises around water tank diameter, water tank radius, the water tank or the water tank area of section.
78. as the water heater of claim 71, wherein the water tank characteristic comprises the water tank height.
79. water heater as claim 71, wherein control circuit comprises microcontroller and storage unit, storage unit has the water heater code, the water heater code to small part based on one of element characteristic and water tank characteristic, and wherein can operate water temperature that microcontroller detects with response at least and water heater code and change dutycycle.
80. a storage-type water heater comprises:
The permanent closure water tank is used for storage of water during water is heated to the set-point temperature;
Water inlet pipe is used for adding cold water to water tank;
Rising pipe is used for discharging the water that process heats from water tank;
At least one stratie, it extends into water tank with the water in the heating water tank;
At least one cooling-water temperature sensor, it can be operated and be used for detecting water temperature; With
Control circuit, it can conduct to stratie with electric power with train of impulses, all follow not time period behind each train of impulses to the stratie conduct electrical power, thereby improved the efficient of the water in the heating water tank, this control circuit comprises microcontroller and software, and this software is used for operating microcontroller and changes dutycycle with water temperature and at least one item of element characteristic, water tank characteristic, water tank external temperature, water uniformity coefficient and water history that response detects.
81. water heater as claim 80, wherein control circuit comprises storage unit, it has to the water heater code of small part based on one of element characteristic and water tank characteristic, and the water temperature that detects with response at least of software operation microcontroller and water heater code and change dutycycle.
82. water heater as claim 81, wherein control circuit comprises storage unit, it has the heating strategy corresponding to the water heater code, and the software operation microcontroller is with response water heater code and obtain heating strategy, and the temperature that detects of response and heating strategy and change dutycycle at least.
83. the water heater as claim 80 further comprises:
Second stratie, it extends into water tank with the water in the heating water tank; With
Wherein control circuit can conduct to second stratie with electric power with train of impulses, all follow not time period behind each train of impulses to the second stratie conduct electrical power, thereby improved the efficient of the water in the heating water tank, and wherein software is further operated the dutycycle that at least one item in water temperature that microcontroller detects with response and element characteristic, water tank characteristic, water tank external temperature, water uniformity coefficient and the water history changes second stratie.
84. as the water heater of claim 83, the train of impulses that wherein offers second stratie is after the train of impulses that offers first stratie.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US09/752,477 | 2001-01-02 | ||
| US09/752,477 US6633726B2 (en) | 1999-07-27 | 2001-01-02 | Method of controlling the temperature of water in a water heater |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN1535404A true CN1535404A (en) | 2004-10-06 |
Family
ID=25026477
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNA018216943A Pending CN1535404A (en) | 2001-01-02 | 2001-12-27 | Proportional band temp control for one or more heating elements |
Country Status (7)
| Country | Link |
|---|---|
| US (2) | US6633726B2 (en) |
| EP (1) | EP1350146A2 (en) |
| CN (1) | CN1535404A (en) |
| AU (1) | AU2002241671A1 (en) |
| CA (1) | CA2366243C (en) |
| MX (1) | MXPA02000278A (en) |
| WO (1) | WO2002053987A2 (en) |
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Also Published As
| Publication number | Publication date |
|---|---|
| CA2366243C (en) | 2011-03-29 |
| MXPA02000278A (en) | 2004-05-21 |
| AU2002241671A1 (en) | 2002-07-16 |
| WO2002053987A2 (en) | 2002-07-11 |
| US20010009609A1 (en) | 2001-07-26 |
| US6795644B2 (en) | 2004-09-21 |
| EP1350146A2 (en) | 2003-10-08 |
| WO2002053987A3 (en) | 2003-03-27 |
| US20030194228A1 (en) | 2003-10-16 |
| CA2366243A1 (en) | 2002-07-02 |
| US6633726B2 (en) | 2003-10-14 |
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